Solar cell modules with improved backskin and methods for forming same

ABSTRACT

A laminated solar cell module with a backskin layer that reduces the materials and labor required during the manufacturing process. The solar cell module includes a rigid front support layer formed of light transmitting material having first and second surfaces. A transparent encapsulant layer has a first surface disposed adjacent the second surface of the front support layer. A plurality of interconnected solar cells have a first surface disposed adjacent a second surface of the transparent encapsulant layer. The backskin layer is formed of a thermoplastic olefin, which includes first ionomer, a second ionomer, glass fiber, and carbon black. A first surface of the backskin layer is disposed adjacent a second surface of the interconnected solar cells. The transparent encapsulant layer and the backskin layer, in combination, encapsulate the interconnected solar cells. An end portion of the backskin layer can be wrapped around the edge of the module for contacting the first surface of the front support layer to form an edge seal.

GOVERNMENT INTEREST

The subject matter described herein was supported in part byPhotovoltaic Manufacturing Technology (PVMaT) Contract No.ZAF-5-14271-09.

FIELD OF THE INVENTION

The invention relates to solar cell modules and methods for forming suchmodules. More particularly, the invention relates to solar cell moduleshaving an improved backskin and methods for forming the backskin ofsolar cell modules.

BACKGROUND

In general, a solar cell module is formed by interconnecting individualsolar cells and laminating the interconnected cells into an integralsolar cell module. More specifically, the module usually includes astiff transparent cover layer made of a polymer or glass material, atransparent front encapsulant which adheres to the cover material and toa plurality of interconnected solar cells, a rear encapsulant which canbe transparent Or any other color, a stiff backskin for protecting therear surface of the module, a protective seal which covers the edges ofthe module, and a perimeter frame made of aluminum which covers theseal. The frame protects the edges of the module when the front cover ismade of glass.

Before the frame is mounted, the module is laminated under heat andpressure. These conditions cause the layers of encapsulant material tomelt, bond to adjacent surfaces, and to literally "encapsulate" thesolar cells. Since crystalline silicon solar cells are usually brittle,the encapsulant serves to protect the solar cells and reduce breakagewhen the module is subject to mechanical stress during field usage.After the lamination process, the frame is attached to the module. Theframe includes mounting holes which are used to mount the framed moduleto an object in the field. The mounting process requires screws, bolts,and nuts and can be accomplished in a variety of ways.

Because existing methods for manufacturing solar cell modules tend to betoo costly, solar electricity is generally not cost-competitive for gridconnected applications. For example, three areas in which manufacturingcosts need to be reduced include: (i) the materials from which themodules are made; (ii) the labor required to deploy these materials; and(iii) the materials and labor associated with mounting the modules inthe field. In particular, the cost of known backskin materials, the costof the aluminum frame, and the cost of labor required for fieldmountings in remote areas are known to be too high.

One known method aimed at reducing solar cell module manufacturing costsincludes eliminating the aluminum frame and using a polymeric materialas both the backskin and the edging. For amorphous silicon solar cellmodules, polymeric frames of a molded thermoplastic material are widelypracticed. Reaction injection molding may be used to mold a polyurethaneframe around an amorphous silicon module. Reaction injection molding isdone in situ (i.e., on the module), and this is a significant costsavings advantage. However, this molding process has severaldisadvantages. For example, this process includes the use of a chemicalprecursor (e.g., isocyanate) which poses environmental hazards. Thisprocess also requires a mold, further adding to the overallmanufacturing cost. In addition, modules made this way tend to be small(e.g., 5-10 Watt size), not the 50-80 Watt size more generally deployedusing aluminum frames. The modules tend to be smaller because of thehigher cost of the mold and the limited strength of the resultingpolymeric frame with its integral mounting holes. As a result, reactioninjection molding is only marginally successful in reducingmanufacturing costs for amorphous silicon solar cell modules.

For crystalline silicon modules, the backskin material is generallyquite costly. There are two widely used backskin materials, both ofwhich tend to be expensive. The most popular material used is aTedlar®/polyester/ethylene vinyl acetate laminate, and the other widelyused backskin material is glass. Two additional layers of material areoften deployed between the solar cells in the module and the backskin,further adding to the manufacturing costs. A rear sheet of the samematerial as the transparent encapsulant, (e.g., Ethylene Vinyl Acetate)and a sheet of "scrim," which allows for efficient air removal duringvacuum lamination, must be applied over the cells before the backskinmaterial is deployed.

Both amorphous and crystalline silicon modules also include a junctionbox which is mounted onto the backskin material and from which allexternal electrical connections are made. Further labor is required tomake connections to the junction box.

A frame, along with an elastomeric edging material, is often used whenthe front support for the module is formed of tempered glass. Thisconstruction protects the edges, as the tempered glass is vulnerable tobreakage if an edge is damaged. While the use of a frame adds durabilityto the solar cell module, it also adds significantly to themanufacturing costs.

The labor intensive process of mounting the module can add significantlyto the overall cost of solar electricity. Modules are mounted byassembling screws, nuts, and bolts to the appropriate mounting holes onthe aluminum frame. However, solar cell modules are often located inremote areas which have no other source of electricity. As such, themounting process often involves attaching the hardware in difficult,awkward and not readily accessible locations such as on rugged terrain,or roof tops.

The foregoing discussion demonstrates that the manufacture of solar cellmodules tends to be too costly and involves too much labor to allow forthe realization of the goal of cost-competitive solar electricity forwide-scale global use.

SUMMARY OF THE INVENTION

The invention features a solar cell module with a backskin materialwhich provides all of the following advantageous features: (i) a strongand weatherable backing for the module; (ii) an edging which can(optionally) eliminate the need for an aluminum frame; (iii) an edgeseal that eliminates the need for any additional seal materials; (iv) arear encapsulant that eliminates the need for a separate rear sheet ofencapsulant material; and (v) the elimination of the need for a scrimlayer to remove air during lamination. The backskin material is easilyformed and molded in situ during the module manufacturing process. Theprimary advantages of solar cell modules utilizing the backskin materialinclude a significant reduction in manufacturing costs and modulemounting costs.

The backskin material is a thermoplastic olefin which may be composed oftwo different kinds of ionomer, mineral filler, and a pigment. Ionomeris a generic name which herein refers to either a co-polymer of ethyleneand methacrylic acid or acrylic acid, which has been neutralized withthe addition of a salt which supplies a cation such as Na+, Li+, Zn++,Al+++, Mg++, etc., or a co-polymer of polyethylene and an acrylate towhich cations such as those listed above have been added. The materialhas the usual covalent bonds which polymers typically have, but also hasregions of ionic bonding. The latter imparts to the materials a built-incross linking. Ionomers are characterized as being tough and weatherablepolymers. The combination of two ionomers produces a known synergisticeffect which improves the water vapor barrier properties of the materialover and above the barrier properties of either of the individualionomer components.

The addition of a mineral filler, such as glass fiber, to the backskinmaterial provides for a lower coefficient of thermal expansion. This isimportant for preserving strong, long lasting bonds to all the adjacentsurfaces in a module which undergoes ambient temperature extremes. Theglass fibers also improve the water vapor and oxygen barrier propertiesof the material and increase the flexural modulus three or four timesover the ionomers themselves. This makes the backskin material verystrong, but still flexible. A pigment, such as carbon black, is added tothe backskin material to provide excellent weathering properties (i.e.resistance to the degradation from the UV light in the solar spectrum).

In one aspect, the invention features a laminated solar cell module. Themodule includes a front support layer formed of light transmittingmaterial, such as glass, and having first and second surfaces. Atransparent encapsulant layer, formed of at least one ionomer, isdisposed adjacent the second surface of the front support layer. A firstsurface of a plurality of interconnected solar cells are disposedadjacent the transparent encapsulant layer. A backskin layer, formed ofa thermoplastic olefin, has a first surface disposed adjacent a secondsurface of the interconnected solar cells. The transparent encapsulantlayer and the backskin layer, in combination, encapsulate theinterconnected solar cells.

A portion of the backskin layer may be wrapped around at least one edgeof the module for contacting the first surface of the front supportlayer, to thereby form an edge seal. The presence of acid functionalityin the ionomers utilized in the backskin material yields the property ofbonding cohesively, not merely adhesively, to various materialsincluding glass, metals, and other polymers. This property is utilizedto provide a wraparound backskin that also serves as an edge sealwithout the need for additional adhesive materials. An optional metallicframe may be securely disposed to at least one edge of the module.

In another aspect, the invention features a method of manufacturing asolar cell module. A front support layer is formed of light transmittingmaterial (e.g., glass). A transparent encapsulant layer, formed of atleast one ionomer, is placed adjacent a second surface of the frontsupport layer. A plurality of interconnected solar cells having firstand second surfaces are positioned adjacent the transparent encapsulantlayer. A backskin layer formed of thermoplastic olefin is placedadjacent a second surface of the interconnected solar cells to therebyform an assembly. The assembly is laminated to form the solar cellmodule. More specifically, the assembly is subjected to heat andpressure to encapsulate the interconnected solar cells with theencapsulant layer and the backskin layer.

A portion of the backskin layer may be wrapped around at least one edgeof the assembly for contacting the first surface of the front supportlayer to form an edge seal. Also, a metallic frame may be securedadjacent at least one edge of the module.

In another aspect, the electrical leads for the module are coated with apolyolefin material (e.g., polyethylene) or a known blend of rubber andpolypropylene. The polyolefin coated leads can be heated and bonded intothe backskin material to form an integral seal. This embodiment (i)provides a superior approach for bringing the leads out of the module,(ii) eliminates the ingress of moisture, and (iii) eliminates the needfor a junction box entirely.

In yet another aspect, a solar cell module employing the above-describedbackskin material is bonded directly to the exterior surface of anarchitectural building material (e.g., aluminum, concrete, stone orglass). The above-described electrical leads can be brought out throughholes in the building material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cross-sectional view of a conventional solar cell modulewith a Tedlar® laminate backskin.

FIG. 1B is a cross-sectional view of a conventional module with a glassbackskin.

FIG. 1C is a cross-sectional view of a conventional module with aperimeter aluminum frame.

FIG. 2 is a cross-sectional view of a solar cell module with theimproved backskin material of the invention.

FIG. 3 is a cross-sectional view of a solar cell module with theimproved backskin material of the invention and mounted in a perimeteraluminum frame using a sealant.

FIG. 4 is a cross-sectional view of a solar cell module with theimproved backskin material wrapped around the assembly to form an edgeseal.

FIGS. 5a-7a are a series of cross-sectional views of a laminationprocess for a solar cell with edge seal and edge protection components.

FIGS. 5b-6b are series of cross-sectional views of another laminationprocess for a solar cell with edge seal and edge protection components.

FIG. 8 illustrates a conventional ground mounting method of a solar cellmodule.

FIG. 9 illustrates another conventional ground mounting method of asolar cell module.

FIG. 10 illustrates a conventional pole mounting method of a solar cellmodule.

FIG. 11 illustrates a conventional roof mounting method of a solar cellmodule.

FIG. 12 illustrates a conventional solar cell mounting method whichincludes ground mounted pole and one axis tracking.

FIG. 13 is a cross-sectional view of a solar cell module of FIG. 7,modified to include mounting bracket bonded to the backskin material.

FIG. 14 is a rear view of the solar cell module of FIG. 13.

FIG. 15 is a cross-sectional view of an extruded mounting bracket.

FIG. 16 is a cross-sectional view of the mounting bracket of FIG. 15slidably engaging a channel bracket.

FIG. 17 is a cross-sectional view of an alternative extruded mountingbracket.

FIG. 18 is a cross-sectional view of the mounting bracket of FIG. 17slidably engaging a channel bracket.

FIG. 19 is a cross-sectional view of the mounting bracket of FIG. 17slidably engaging a channel bracket using a bolt.

FIG. 20 is a cross-sectional view of the mounting bracket of FIG. 17slidably engaging a channel bracket using a rivet.

FIG. 21 is an illustration of a solar cell module with polyolefincovered leads bonded directly to the backskin.

FIG. 22 is an illustration of the module of FIG. 4 bonded directly tothe outer surface of an architectural building material.

DETAILED DESCRIPTION

FIGS. 1A, 1B, and 1C are cross-sectional views of conventional solarcell modules. FIG. 1A shows a module with a transparent front supportlayer 10 of glass or polymer disposed on a transparent encapsulant layer12. The encapsulant layer is disposed on an array of interconnectedsolar cells 14, which is disposed on a scrim layer 16. The scrim layeris disposed on a rear encapsulant layer 18, which is disposed on abackskin 20. The backskin 20 may be a Tedlar® laminate of aboutten-thousandths of an inch thickness. FIG. 1B shows another modulehaving the same configuration as the module shown in FIG. 1A, exceptthat the backskin 22 is formed of a sheet of glass. The assembly shownin FIG. 1A or FIG. 1B is laminated by subjecting the assembly to heatand pressure in a vacuum laminator using a known process.

Referring to FIG. 1C, the scrim layer 16 is absorbed into the rearencapsulant sheet 18 during lamination and is not therefore shown. Aperimeter frame 26, typically aluminum, is mounted to surround the edgesof the module and a sealing material 28 seals the edges. The sealingmaterial 28, in the form of a strip of tape or a caulking type compound,is applied to the edges. Subsequently, sections of the perimeter frame26 are fastened onto the module and joined together at the corners.

The invention features a solar cell module having an improved backskinmaterial which significantly reduces manufacturing costs. This isaccomplished by eliminating certain materials which are conventionallyused in the construction of prior art modules and by simplifying thesteps required to make the module. More particularly, the improvedbackskin material eliminates the need for a rear encapsulant layer, fora scrim layer, for a sealing strip or sealing material at the moduleedges, and for the requirement of a perimeter frame of aluminum.

FIG. 2 shows a solar cell module including the improved backskinmaterial. The module 30 includes a front support layer 32 formed oflight transmitting material (e.g., glass) and having front and rearsurfaces (32a, 32b). A transparent encapsulant layer 34 is disposed overthe rear surface 32b of the front support layer. A first surface 36a ofa plurality of interconnected solar cells 36 is disposed over thetransparent encapsulant layer 34. A flexible backskin layer 38 has afirst surface 38a disposed adjacent the second surface 36b of theinterconnected solar cells. A laminated module is formed by placing themodule in a laminator and subjecting it to heat and pressure. Thelamination process causes the transparent encapsulant layer 34 and thebackskin material 38 to melt and bond to the interconnected solar cells36 and other adjacent surfaces. Once the lamination process is complete,the transparent encapsulant layer 34 and the backskin layer 38, incombination, encapsulate the interconnected solar cells 36.

In accordance with the invention, the backskin material 38 is athermoplastic polyolefin including a mixture of at least two ionomers.In one detailed embodiment, the backskin is a flexible sheet ofthermoplastic polyolefin which includes a sodium ionomer, a zincionomer, 10-20% glass fibers, and about 5% carbon black and has athickness of about 0.040 inches. The carbon black is added to provideexcellent resistance to weathering effects due to UV sunlight andatmospheric conditions. Thus, the material 38 combines the features offlexibility, elasticity, strong cohesive bonding to certain surfaces(e.g., glass, metal and polymer), toughness, and excellent resistance toUV light degradation. As a result of these properties and advantages,the use of this material results in significant cost savings in themanufacture of solar cell modules.

Referring to FIG. 3, the module can be fitted with a frame. In oneembodiment, a perimeter frame 40 of metallic material can be secured tothe module 30. A sealant 42 may be applied to the module edges to sealthe frame 40 to the module 30. Alternatively, the backskin can bewrapped around the edges of the module (see, FIG. 4), and the frameheated and bonded directly to the wrapped portion of the backskinmaterial without any adhesive or bonding agent. In another embodiment,instead of using a perimeter frame, a plurality of mounting brackets areheated and then bonded directly to the backskin material without anyadhesive or bonding agent. These aluminum pieces then become slideswhich allow the module to be slid into place by sliding it along channelbrackets (see, FIGS. 13-18).

FIG. 4 shows a solar cell module 44 in which portions 46 of the improvedbackskin material 38 is wrapped around the edges of the assembly andbonds to the solar cells 36, the transparent front encapsulant 34 andthe front support layer 32. In this configuration, the backskin material38 provides four functions: (i) the backskin, (ii) the rear encapsulant,(iii) the edge protector, and (iv) the edge sealant. As notedpreviously, the module 44 can be fitted with various types of frames.

FIGS. 5a-7a show a processing sequence used to form the solar cellmodule shown in FIG. 4. Referring to FIG. 5a, a sheet of backskinmaterial 38 about one inch wider than the cover layer 32 is positionedadjacent the interconnected solar cells 36. Narrow strips of thebackskin material 38c are laid down along the perimeter of the coverlayer 32 with the strips overlapping at the corners. The assembly isthen placed in a laminator and subjected to heat and pressure withtemperatures on the order of 150° C. FIG. 6a illustrates the laminatedmodule. As shown, the backskin 38 and perimeter strips 38c havecompletely melted together and formed a tight seal along the edge 32c ofthe front surface of the cover layer 32. Without the need for a mold ofany kind, the lamination of a module with the improved backskin yieldsedge protection and edge sealing. Any excess backskin material caneasily be trimmed off to provide the finished module illustrated in FIG.7a.

FIGS. 5b-6b show a processing sequence used to form another solar cellmodule. Referring to FIG. 5b, the module is the same as that describedin connection with FIG. 5a, except that a plurality of narrow strips ofthe backskin material 38c are stacked along the perimeter of the coverlayer 32. The assembly is then placed in a laminator and subjected toheat and pressure. FIG. 6b illustrates the laminated module. As shown,the backskin 38 and perimeter strips 38c have completely melted togetherand formed a tight seal along the front surface of the cover layer 32.With this process, there is no need to trim excess backskin material asdescribed in connection with FIG. 6a.

FIGS. 8-12 illustrate conventional means for mounting modules. In FIG.8, the solar cell module 50 and the aluminum frame 52 are mounted tometallic mounts 54. These mounts 54 are, in turn, mounted to a metallicstructure 56 or to cement. In FIG. 9, the module 50 is connected to asupport member 58 which, in turn, is joined to other metal supportmembers 60, 62. In FIG. 10, cross members 64 are mounted to other pieces66 and directly to a pole 68. In FIG. 11, the module 50 is placed onjacks (or standoffs) 70 which are attached to the roof 72. FIG. 12 showsa pole mounting scheme for tracking in which modules 50 are mounted in ametal structure 52 connecting the module frames.

The invention features a solar cell module including an improvedmounting structure. Referring to FIG. 13, a solar cell module 80includes a front support layer 82, a transparent front encapsulant 84,solar cells 86 and the improved backskin material 88. As shown, thebackskin 88 is wrapped around the edges of the assembly and bonds to thesolar cells 86, the transparent front encapsulant 84 and the frontsupport layer 82. Extruded mounting brackets 90, which may be aluminumor polymeric material, are heated and bonded directly to rear surface ofthe backskin material. FIG. 14 is a plan view of the module 80 includingfour mounting brackets 90. In another embodiment, the module may includetwo mounting brackets (not shown) extending across the rear surface ofthe backskin material.

FIGS. 15 and 17 illustrate two possible configuration of extrudedmounting brackets (92, 94). In both configurations, the brackets includetwo C-shaped members (92a, 92b or 94a, 94b) connected by a linearmember. As described below, these brackets slidably engage a channelbracket for mounting a module. The C-shaped members (92a, 92b or 94a,94b) provide stiffness and permit secure engagement to the channelbracket. The linear member is multifunctional in that it allows forvarious mounting configurations to the channel bracket as explainedbelow (see FIGS. 16, 19 and 20). Also, a molded plastic insert (notshown) may be inserted adjacent the linear member and between theC-shaped members. The insert wraps around the bottom and sides of theC-shaped members and engages the channel bracket to accommodatetolerance differences along the channel bracket and C-shaped members.

FIG. 16 illustrates a module mounted to a channel bracket disposed on astructure (e.g., a roof, a pole, or the ground). A module 80 includesincluding a mounting bracket 92 directly mounted to the backskin 88. TheC-shaped members 92a, 92b slidably engage a channel bracket 96 securedto a structure (not shown). As such, the module 80 can be easily slidalong the channel bracket 96 to a desired location. FIG. 18 illustratesa module mounting configuration using the mounting bracket 94 shown inFIG. 17.

FIGS. 19 and 20 illustrate alternative mounting configurations. In FIG.19, the module 80 includes including an inverted mounting bracket 92directly mounted to the backskin 88. The C-shaped members 92a, 92b aresecured via a bolt 98 to the channel bracket 96. In FIG. 20, an invertedmounting bracket 94 is secured via a rivet 100 to the channel bracket96.

FIG. 21 illustrates an embodiment in which the electrical leads for themodule are coated with a polyolefin material (e.g., polyethylene) or aknown blend of rubber and polypropylene. The two electrical leads (102a,102b) are covered with a polyolefin material (101a, 10lb) and bondedinto the backskin material (103a, 103b). As such, the coated leads forman integral seal and no junction box is required on the module.

FIG. 22 illustrates an embodiment in which the module 104 (see FIG. 4)is bonded directly to the exterior surface of an architectural buildingmaterial 105 (e.g., aluminum, concrete, stone or glass). The exteriorsurface (or the backskin material) is heated and the module is bondeddirectly to the building material. The electrical leads (not shown),formed as described in connection with FIG. 21, are brought out throughholes 106 in the building material and extend into the interior of thebuilding.

EQUIVALENTS

While the invention has been particularly shown and described withreference to specific preferred embodiments, it should be understood bythose skilled in the art that various changes in form and detail may bemade therein without departing from the spirit and scope of theinvention as defined by the appended claims.

I claim:
 1. A laminated solar cell module comprising:a from supportlayer formed of light transmitting material and having first and secondsurfaces; a transparent encapsulant layer disposed adjacent the secondsurface of the front support layer; a plurality of interconnected solarcells having a first surface disposed adjacent the transparentencapsulant layer; and a backskin layer formed of a thermoplastic olefincomprising at least a first ionomer and a second ionomer and having afirst surface disposed adjacent a second surface of the interconnectedsolar cells; wherein the transparent encapsulant layer and the backskinlayer, in combination, encapsulate the interconnected solar cells. 2.The solar cell module of claim 1 wherein the thermoplastic olefinfurther comprises a mineral filler.
 3. The solar cell module of claim 2wherein the mineral filler is glass fiber.
 4. The solar cell module ofclaim 1 wherein the thermoplastic olefin further comprises a pigment. 5.The solar cell module of claim 4 wherein the pigment is carbon black. 6.The solar cell module of claim 1 wherein a portion of the backskin layeris wrapped around at least one edge of the module for contacting thefirst surface of the front support layer, to thereby form an edge seal.7. The solar cell module of claim 1 wherein the backskin layer isflexible.
 8. The solar cell module of claim 1 wherein the front supportlayer comprises glass.
 9. The solar cell module of claim 1 wherein thetransparent encapsulant layer comprises at least one ionomer.
 10. Thesolar cell module of claim 1 further comprising a metallic framesecurely disposed adjacent at least one edge of the module.
 11. A methodof manufacturing a solar cell module comprising:providing a frontsupport layer formed of light transmitting material and having first andsecond surfaces; placing a transparent encapsulant layer adjacent thesecond surface of the front support layer; positioning a plurality ofinterconnected solar cells having first and second surfaces adjacent thetransparent encapsulant layer; placing a backskin layer formed ofthermoplastic olefin comprising at least a first ionomer and a secondionomer adjacent a second surface of the interconnected solar cells tothereby form an assembly; and laminating the assembly to form the solarcell module.
 12. The method of claim 11 wherein the laminating stepcomprises subjecting the assembly to heat and pressure to encapsulatethe interconnected solar cells with the encapsulant layer and thebackskin layer.
 13. The method of claim 11 further comprising wrapping aportion of the backskin layer around at least one edge of the assemblyfor contacting the first surface of the front support layer to form anedge seal.
 14. The method of claim 11 further comprising seeing ametallic frame adjacent at least one edge of the module.
 15. A laminatedsolar cell module comprising:a rigid front support layer formed of lighttransmitting material and having first and second surfaces; atransparent encapsulant layer having a first surface disposed adjacentthe second surface of the front support layer; a plurality ofinterconnected solar cells having a first surface disposed adjacent asecond surface of the transparent encapsulant layer; a backskin layerformed of a thermoplastic olefin comprising at least a first ionomer anda second ionomer and having a first surface disposed adjacent a secondsurface of the interconnected solar cells, a portion of the backskinlayer being wrapped around at least one edge of the module forcontacting the first surface of the front support layer to form an edgeseal; wherein the transparent encapsulant layer and the backskin layer,in combination, encapsulate the interconnected solar cells.
 16. Thesolar cell module of claim 15 wherein the thermoplastic olefin furthercomprises a mineral filler and a pigment.
 17. The solar cell module ofclaim 15 wherein the backskin layer is flexible.
 18. A method ofmanufacturing a solar cell module comprising:providing a front supportlayer formed of light transmitting material and having first and secondsurfaces; placing a transparent encapsulant layer adjacent the secondsurface of the front support layer; positioning a plurality ofinterconnected solar cells having first and second surfaces adjacent thetransparent encapsulant layer; placing a backskin layer formed ofthermoplastic olefin comprising at 1east a first ionomer and a secondionomer adjacent a second surface of the interconnected solar cells tothereby form an assembly; wrapping an end portion of the backskin layeraround at least one edge of the assembly for contacting the firstsurface of the front support layer, to form an edge seal; and subjectingthe assembly to heat and pressure to (i) bond the encapsulant layer andthe backskin layer to the interconnected solar cells, and (ii)encapsulate the interconnected solar cells with the encapsulant layerand the backskin layer, to form the solar cell module.
 19. A laminatedsolar cell module comprising:a stiff front support layer formed of lighttransmitting material and having first and second surfaces; transparentencapsulant layer formed of at least one ionomer and disposed adjacentthe second surface of the front support layer; a plurality ofinterconnected solar cells having a first surface disposed adjacent thetransparent encapsulant layer; a flexible backskin layer formed of athermoplastic olefin comprising at least a first ionomer and a secondionomer and having a first surface disposed adjacent a second surface ofthe interconnected solar cells; wherein the transparent encapsulantlayer and the backskin layer, in combination, encapsulate theinterconnected solar cells.
 20. A method of manufacturing a solar cellmodule comprising:providing a stiff front support layer formed of lighttransmitting material and having first and second surfaces; placing atransparent encapsulant layer formed of at least one ionomer adjacentthe second surface of the front support layer; positioning a pluralityof interconnected solar cells having first and second surfaces adjacentthe transparent encapsulant layer; placing a flexible backskin layerformed of thermoplastic olefin comprising at least a first ionomer and asecond ionomer adjacent a second surface of the interconnected solarcells to thereby form an assembly; and subjecting the assembly to heatand pressure to encapsulate the interconnected solar cells with theencapsulant layer and the backskin layer, to thereby form the solar cellmodule.